Molding, coating, filling, impregnating, and binding



UNITED STATES PATENT OFFICE ISADORE SIDNEY mnnnmorr, or PHILADELPHIA, rmmsnlvmra. assmnon ro xnmmn'me, A conronnrron or DELAWARE MOLDING, COATING, FILLING, IMPREGRATING, AND BINDING No Drawing.

This invention relates to the production of molded, coated or impregnated substances or substances having. two or more of these characteristics. The substances will have their surfaces relatively resistant to water, fire, acids, alkalis and the like. Likewise the interior or entire body of the substance maybe also relatively resistant to water, fire, acids, alkalis and the like.

The invention is useful for impregnating Wood fiber and other porous substances, coating porous substances as well as Wood and metallic surfaces, making compound or molded lumber, making laminated prod- 1m and veneer, finishing Wood products and metallic surfaces, making composition articles of nonlaminated material and resin binder and making composition board of paper and duck and in other. ways.

More specifically the invention relates to the production of articles consisting of or' comprising Wood or other fibrous or cellular materials coated, impregnated or saturated with a resinous material which is substantially insoluble and infusible and whichmay act as a" coating or filling to finish and protect the wood or other fibrous or cellular material. It may also be used to cause it to adhere to other .bodies. The completed 0 product may consist of a unitary structure or a mass of fibrous or cellular material or layers of fibrous or cellular material which may be all or part only coated, impregnated or saturated with the resinous material orheld 5 together thereby. The resinous material used is made from peat as a base and consists of the condensation product resultingfrom causing an alkaline solution of peat to react with an aldehyde and a phenolic body substantially as described .in Patent Number 1,681,155 issued August 14, 1928.

In carrying out the invention the resinous material may be associated with such fibrous or cellular or porous material as paper, paper pulp, Wood pulp, paper board, textile fabrics, card board, parchmentized fibre, leather, ground leather, saw dust, wood flour, ground Wood, exploded wood, linters, flock,

Application filed September 25, 1928. serial lqo. 808,848.

asbestos fibers, china clay, talc, whiting, iron, oxide and other pigments, textile or granular material; For some pur oses metals, stones, or metal or stone sur aces may be treated with the resinous material. Two or more of these various materialsma be em' ployed or m1xed, associated or com ined in a single product.

In the treatment the esin may be employed in a liquid, syrupy, solvedor powdered form or state. In any of these forms except when powdered, the resin maybe used to impregnate or saturate clothgtextile' material, paper fiapfj h eets, card board or any othgr sugh sbset...material. The powdered resinous material when mixed with .them may be used as a binder or adhesive for such loose granular or owdered materials as wood flour, talc, woo pulp, round cork,

ground leather and the like.

hese loose,

granular or powdered substances are also adapted to treatment with the resinous ma-= terlal in the other forms. Likewise dered form of the resin may be spreader sprinkled on solid or sheet materials and by appropriate treatment coat them or bind g. '75."- The compositions described comprisecel- 1 them together.

lular, fibrous or powdered material in c'om-- bination with a binding, coating or impregnating resin. The composition masses have the virtue of being hard, strong and good electrical insulators.

As one method of carrying out the-invehtion synthetic resin may be first allowed'to begin to form according to the process de-' scribed in Patent Number 1,681,155 andas the reaction product begins to approach the as; I

syrupy consistency there may be added 'fibrous or cellular material in the dry form or slightly moistened with-water or other liquid in any desired proportion. The cellular or fibrous materials may be this caused to swell and in so doing introduce the binder or resinous materials thoroughly about and into the said material and its particles. The mass thus formed may be of about the consistency of dough and so maybe formed or} pressed into molds and subjected to a pressure of from about 1000 to 10000 pounds per, square inch while being raised to atem erature of from about to C. by w ich the present process there is no such se and in this dry condition pressed into moldsor suitable containers and pressed and heated as indicated above for the final transformation.

In the usual phenol-formaldehyde conen a formaroduct which two 1i uids wi separate or stratify on standing w ich may indicate that the condensa-' tion product is not soluble in the liquid. In

the process of making the peathenol-formaldehyde r'esin,'there is no suc separation, as the condensation product seems to remain more or less evenly distributed in the entire solution. If any of the above mentioned fill-v ing materials are added to the heretofore known phenol-formaldeh de resin, while in the process of making, t e filling materials would be first wetted y the water, since water has a greater affinity for the sald filhng materials than the resin has, therefore the resin might have little or no opportunity to replace the water and penetrate the fibrous cellular filling materials. Since thereus a separation of two liquids which may indicate that the condensationproduct is not soluble in water, it may be that the water penetrating the said fibrous material really, retards the penetration of the resinous material. In aratlon and when the fibrous material is ad ed it is immediately penetrated by the resinous material. There is no se aration of resin from water in the process 0 making and since water seems to have a great ailinit for fibrous cellular material in this way w en it erle-- trates the cellular structure it carries with it resinous material. The first depositv of resinous material may pave the way for and.

' tion of the can be used lead in the more concentrated'resinous matepart of theprocess thus producing a thorough y saturated final product. Thus an aqueous solueat-phenol-formaldehyde res1n For molding, coating, filling, impregnating and binding.

The resin in the stage in which it is syrupy when cold and liquid when hot may be used to coat or impregnate sheets of paper, parch ment, paper board, laminated paper and the like b I brushing, spra in or passing through the bath: or in iiy other suitable way. These individual sheets may be individually dried and then heated and pressed as-indicated above for the final reduction of the resin or they may be individually dried each other by piling one on another and formed into a compact laminated mass by the heat and ressuretreatment indicated, or the undrie sheets may be similarly formed into a laminated pile and caused to adhere by the heat and pressure treatment indicated.

Composition boardor sheets may be made up of untreated layers alternately with treated layers, the resin in or on the treated layers being relied on to cause the sheets to adhere together and make a substantially unitary laminated structure from the whole after the final transforming heat treatment under ressure. treated ayers maybe applied as coatings or veneers to treated or untreated bodies. Thus Similarly one or more a layer of saturated material may be applied to-stone or metal articles or they may be merely covered with the unadulterated resin to furnish a noncorrosive and/or ornamental surface. Saturated materials or those having a. slightly inset surface coat may have the adhering surface resin cut or scraped off thus leaving a hard impregnated or filled surface capable of taking a satisfactory finish. 4

Another method is'to allow the formationv of the resin to progress further until it has reached the syrupy state when hot. In this state the resin will be solid when cold. This hot syrupy resin ordinarily may not readily enter into or saturate bodies or sheets, especially if they are thick. While the resin is hot and in the syrupy condition a solvent may be-added in the proportion of about one part of resin to about 2 to 5 parts of solvent. This will make what will be termed a concentrated solution. A similar solution to which solvent has-been added till there is but about 'one part of resin to about 10 to 20 parts of taining the concentrated solution of the resin when the material will become more or less thoroughly saturated therewith and may be be dried or otherwise treated between its subjection to the dilute solution and its subjection to the concentrated solution. After being subjected to both solutions it may be dried in an oven and then heated to from about 120 to 150 C. under pressure of from about 1000 to 10000 pounds pressure until the insoluble and infusible form of the resin is obtained. The treated material can After removed. Preferably the material will not be heated and submitted to pressure as indi-. I

cated above without subjecting it to the pre liminary drying in an oven. In coating, saturating or impregnating fibrous and cellular materials, sheets, paper board etc. it is found to be better to first treat the materials with the dilute resin solution and then follow with a treatment with the concentrated resin solution.

A mass of fibrous or cellular material such as paperpnln and the like can be soaked first with the dilute resinous solution and then in the concentrated resinous solution. The mass of saturated or impregnated fibre and resin can be forced into a mold and molded by heat and pressure (about 120 to 150 C. and about 1000 to 10000 pounds per square inch) to any desired shape. The heat and pressure pressed into any convenient or desired form help to brin about the insoluble and infusible form. r thesaturated or impregnated mass may be heated until it dries. It may be then powdered and may be shaped and with the aid of heat and pressure.

When the materials are treated with the partly formed resin or even with the concentrated solution frequently the impregnation or penetration w1ll be partial and incomplete. This is especially so when the material to be treated is in thick sheets or blocks.

- eration even with materials usually hard to deal with in any form other than the thinnest possible sheets or strips or fragments.

There are various solvents for the partially formed resins at the stages when solution is indicated above. For both the dilute and concentrated solution alcohol or acetone, etc., are suitable and preferred. The solution may take place in a cold solvent but it is preferably aided by heat. The solution may eiiectively saturate or impregnate the materials treated when cold but the action is hastened and sometimes improved by heating the solutionor the materials treated or both.

When a solvent is used the saturated or impregnated mass if desired may be heated or otherwise treated to remove the solvent before proceeding with the further steps in the treatment.

Y Laminated boards or sheets of anydesired thickness and of any desired composition or combination of substances may be built up by any of the methods indicated. The above described materials can be use for a wide variety of thin s. The product can serve as a rawmachinab e materialwhich can-be worked by any suitable means into any desired-form. The products are of a high product.

mechanical strength and can'be used for numerous mechanical or' electrical purposes. The resm derived from the peat base -1s rela- I tively cheap and the resultant product made therewith is relatively cheap. Thus the material'described above has improved characteristics over products now in use and may replace or'take the place of other more expensive substances in a satisfactory economical way and without the loss of any required or desirable characteristics. V

While various "specific details of materials, quantities, temperatures, pressures and other items of procedure, operation or result have been set out to clearly disclose the invention it is to be fully'understood that they are for illustrative purposes only and are not to be taken as limiting the invention.

'1 claim as my invention:

1. The method of saturating or impregnatingmaterialwith the condensation prodnot of an alkaline solution of peat reacting with "an aldehyde and a phenolic body comprising, forming a solution of about one part i of the condensation product when the mass is in a syrupy state to about 10 to 20 parts of solvent, treating the material to be impregnated with the solution, making a solution of about one part of the syrupy mass to about 2 to 5 parts of solvent, treatin the material with the last mentioned solution, and completing the reaction by heating and pressing the im regnated material.

2. T e method of saturating or impreg nating material with the condensation pro uct of an alkaline solution of peatreacting with an aldehyde and a phenolic body comprising, treating the material with a solution of about one part of the condensation product when the mass is in a syrupy state to.

about 10 to 20 parts of solvent, treating the material with a solution of about one part of the mass to about 2 to 5 parts of solvent, and completing the reaction by heating and pressing the impre ated material.

. 3. The method 0 saturating or impregnating material with thecondensation product of an alkaline solution of peat reacting with an aldehyde and a phenolic body comprising impregnating the material with a dilute solution of the condensation product and subsequently impregnating the material with a concentrated solution of the condensation 4. The ste in'saturatin cellular material with the con ensation pro uct of an alk ine solution of eat reactmg with an aldeh do and a pheno ic body com rising impregnating the material with'a di ute solution of the condensation product to pave the ay and lead in a subsequent'concentrated sol tion of the condensation product and treating the material with a concentrated solution of the resin which isled in b the dilute solutiom ISADORE SIDN Y MELLANOFRX-gg 

